Interlocking co-molded helmet energy management liner

ABSTRACT

A helmet includes a helmet body with an outer shell and an in-molded energy management liner inside the outer shell. The in-molded energy management liner may include an inner liner of a first material and an outer liner of a second material different from the first material, with at least one hole through the inner liner, an inside surface, an outside surface, and sides connecting the inside surface with the outside surface. The outer liner formed around the inner liner such that the outer liner extends through the at least one hole and around at least two of the sides of the inner liner, covering a majority of the outside surface and at least a portion of the inside surface, and both the inner liner and the outer liner are exposed on an inside of the in-molded energy management liner.

TECHNICAL FIELD

Aspects of this document relate generally to assembling multiple helmetliners, and more specifically to a helmet comprising a co-molded energymanagement liner and methods for assembling such a helmet.

BACKGROUND

Protective headgear and helmets have wide uses. Multiple liners are usedfor comfort and protection. To assemble a multi-liner helmet, the linersare glued together or fastened together through components like plasticparts or pins, which requires additional manufacturing parts and steps.Further, the glue or the fastening components may deteriorate with timeor use and lose its strength in holding the liners together. As aresult, the multiple liners may separate and fall apart.

SUMMARY

According to an aspect of the disclosure, a helmet may comprise a helmetbody and a fit system, an outer shell and an in-molded energy managementliner inside the outer shell. The in-molded energy management liner mayinclude an inner liner of expanded polypropylene (EPP) and an outerliner of expanded polystyrene (EPS) with at least one hole through theinner liner, an inside surface, an outside surface, and sides connectingthe inside surface with the outside surface. The outer liner may beformed around the inner liner such that the outer liner extends throughthe at least one hole and around at least two of the sides of the innerliner, covering a majority of the outside surface and at least a portionof the inside surface. The fit system is disposed within the in-moldedenergy management liner and coupled to the helmet body.

Particular embodiments may comprise one or more of the followingfeatures. One or more standoffs extending outward through the outsidesurface of the outer liner. Both the inner liner and the outer liner maybe exposed on an inside of the in-molded energy management liner. Theouter liner may engage the inner liner mechanically and without achemical bond. The outer liner extending at least partially around allof the sides of the inner liner.

According to an aspect, an in-molded energy management liner maycomprise an inner liner of expanded polypropylene (EPP) and an outerliner of expanded polystyrene (EPS). The inner liner of expandedpolypropylene (EPP) may have at least one hole through the inner liner,an inside surface, an outside surface, and sides connecting the insidesurface with the outside surface. The outer liner of expandedpolystyrene (EPS) may be formed around the inner liner such that theouter liner extends through the at least one hole and around at leasttwo of the sides of the inner liner, covering a majority of the outsidesurface and at least a portion of the inside surface.

Particular embodiments may comprise one or more of the followingfeatures. One or more standoffs extending outward from the inner linerthrough the outside surface of the outer liner. Both the inner liner andthe outer liner may be exposed on an inside of the in-molded energymanagement liner. The outer liner may engage the inner linermechanically and without a chemical bond. The outer liner may extend atleast partially around all of the sides of the inner liner.

According to an aspect, a method of assembling a multi-liner helmet maycomprise injecting a first material into an inner-liner mold to form aninner liner, placing the inner liner in an outer-liner mold, andinjecting a second material different from the first material into theouter-liner mold to form an outer liner around the inner liner, whereinthe outer liner extends through at least one hole in the inner liner andaround at least two of sides of the inner liner, covering a majority ofan outside surface of the inner liner, and both the outer liner and theinner liner are exposed on an inside of an in-molded energy managementliner comprising the inner liner and the outer liner.

Particular embodiments may comprise one or more of the followingfeatures. The first material may be expanded polypropylene (EPP) and thesecond material may be expanded polystyrene (EPS). The inner liner maycomprise standoffs extending outward and injecting a second materialcomprises injecting the second material such that the standoffs extendoutward through an outside surface of the outer liner.

According to an aspect, a helmet may comprise a helmet body with anouter shell and an in-molded energy management liner inside the outershell that includes an inner liner of a first material and an outerliner of a second material different from the first material. The innerliner may have at least one hole through the inner liner, an insidesurface, an outside surface, and sides connecting the inside surfacewith the outside surface. The outer liner may be formed around the innerliner such that the outer liner extends through the at least one holeand around at least two of the sides of the inner liner, covering amajority of the outside surface and at least a portion of the insidesurface, and both the inner liner and the outer liner are exposed on aninside of the in-molded energy management liner.

Particular embodiments may comprise one or more of the followingfeatures. A fit system disposed within the in-molded energy managementliner and coupled to the helmet body. The first material may be EPP andthe second material may be EPS. The inner liner may comprise one or morestandoffs extending outward through the outside surface of the outerliner. The outer liner may engage the inner liner mechanically andwithout a chemical bond. The outer liner may extend at least partiallyaround all of the sides of the inner liner.

Aspects and applications of the disclosure presented here are describedbelow in the drawings and detailed description. Unless specificallynoted, it is intended that the words and phrases in the specificationand the claims be given their plain, ordinary, and accustomed meaning tothose of ordinary skill in the applicable arts. The inventors are fullyaware that they can be their own lexicographers if desired. Theinventors expressly elect, as their own lexicographers, to use only theplain and ordinary meaning of terms in the specification and claimsunless they clearly state otherwise and then further, expressly setforth the “special” definition of that term and explain how it differsfrom the plain and ordinary meaning. Absent such clear statements ofintent to apply a “special” definition, it is the inventors' intent anddesire that the simple, plain, and ordinary meaning to the terms beapplied to the interpretation of the specification and claims.

The inventors are also aware of the normal precepts of English grammar.Thus, if a noun, term, or phrase is intended to be furthercharacterized, specified, or narrowed in some way, such noun, term, orphrase will expressly include additional adjectives, descriptive terms,or other modifiers in accordance with the normal precepts of Englishgrammar. Absent the use of such adjectives, descriptive terms, ormodifiers, it is the intent that such nouns, terms, or phrases be giventheir plain, and ordinary English meaning to those skilled in theapplicable arts as set forth above.

Further, the inventors are fully informed of the standards andapplication of the special provisions of 35 U.S.C. § 112, ¶6. Thus, theuse of the words “function,” “means” or “step” in the DetailedDescription or Description of the Drawings or claims is not intended tosomehow indicate a desire to invoke the special provisions of 35 U.S.C.§ 112, ¶6, to define the invention. To the contrary, if the provisionsof 35 U.S.C. § 112, ¶6 are sought to be invoked to define theinventions, the claims will specifically and expressly state the exactphrases “means for” or “step for”, and will also recite the word“function” (i.e., will state “means for performing the function of[insert function]”), without also reciting in such phrases anystructure, material, or acts in support of the function. Thus, even whenthe claims recite a “means for performing the function of . . . ” or“step for performing the function of . . . ,” if the claims also reciteany structure, material, or acts in support of that means or step, or toperform the recited function, it is the clear intention of the inventorsnot to invoke the provisions of 35 U.S.C. § 112, ¶6. Moreover, even ifthe provisions of 35 U.S.C. § 112, ¶6, are invoked to define the claimedaspects, it is intended that these aspects not be limited only to thespecific structure, material, or acts that are described in thepreferred embodiments, but in addition, include any and all structures,material, or acts that perform the claimed function as described inalternative embodiments or forms in the disclosure, or that arewell-known present or later-developed, equivalent structures, material,or acts for performing the claimed function.

The foregoing and other aspects, features, and advantages will beapparent to those artisans of ordinary skill in the art from theDETAILED DESCRIPTION and DRAWINGS, and from the CLAIMS.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations will hereinafter be described in conjunction with theappended drawings, where like designations denote like elements, and:

FIG. 1 is a perspective view of a multi-liner helmet;

FIG. 2 is a front perspective view of an energy management liner;

FIG. 3 is a cross-sectional side view of the energy management linershown in FIG. 2, where the outer liner is shown as transparent;

FIG. 4 is the cross-sectional side view of the energy management linershown in FIG. 2, where the outer liner is shown as solid;

FIG. 5 is a flow chart of a method for assembling a multi-liner helmet.

DETAILED DESCRIPTION

While this disclosure includes embodiments in many different forms, theyare shown in the drawings and will herein be described in detailedparticular embodiments with the understanding that the presentdisclosure is to be considered as an exemplification of the principlesof the disclosed methods and systems, and is not intended to limit thebroad aspect of the disclosed concepts to the embodiments illustrated.

Protective head gear and helmets have been used in a wide variety ofapplications and across a number of industries including recreation,sports, athletics, construction, mining, military defense, and others,to prevent damage to users' heads and brains. Damage and injury to auser can be prevented or reduced by preventing hard objects, sharpobjects, or both, from directly contacting the user's head, and also byabsorbing, distributing, or otherwise managing energy of an impactbetween the object and the user's head. Straps or webbing are typicallyused to allow a user to releasably wear their helmet, and to ensure thehelmet remains on the user's head during an impact.

Protective headgear or helmets can be used for a snow skier, a cyclist,football player, hockey player, baseball player, lacrosse player, poloplayer, climber, auto racer, motorcycle rider, motocross racer,snowboarder or other snow or water athlete, sky diver or any otherathlete, recreational or professional, in a sport. Other non-athleteusers such as workers involved in industry, including without limitationconstruction workers or other workers or persons in dangerous workenvironments can also benefit from the protective headgear describedherein, as well as the system and method for providing the protectivehead gear.

Helmets function to provide protection while minimizing interferencewith an activity. The shape of a helmet may be adapted to provide bothprotection and comfort (e.g. ventilation, size, etc.). Some helmets aremade of two or more bodies of energy-absorbing material formed in shapesthat would be difficult, if not impossible, to achieve in a singlemolded piece.

Various implementations and embodiments of protective helmets accordingto this disclosure comprise a protective shell. The protective shell maybe formed of an energy absorbing material such as expanded polystyrene(EPS), expanded polyurethane (EPU), expanded polyolefin (EPO), expandedpolypropylene (EPP), or other suitable material. The energy absorbingmaterial can be used as part of a hard-shell helmet such as skate buckethelmets, motorcycle helmets, snow sport helmets, football helmets,batting helmets, catcher's helmets, or hockey helmets, and include anadditional outer protective shell disposed outside, or over, theprotective shell. In hard shell applications, the energy absorbingmaterial may comprise one or more layers of EPP and provide moreflexibility. Alternatively, the energy absorbing material may be part ofan in-molded helmet such as a bicycle helmet or cycling helmet. An outershell layer, such as a layer of stamped polyethylene terephthalate or apolycarbonate shell, may be included on an outer surface of theprotective shell of the helmet and be bonded directly to the energymanagement liner.

Contemplated as part of this disclosure is a multi-liner helmet having aco-molded energy management liner, as well as a method of assemblingsuch a helmet.

A helmet 100 comprises a helmet body 102 (FIG. 1). A helmet 100 mayfurther comprise a fit system 400. The helmet body 102 comprises anouter shell 104 and an in-molded or co-molded energy management liner,energy absorbing liner, or impact liner 200 inside the outer shell 104.The fit system 400 may be disposed within the in-molded energymanagement liner 200 and coupled to the helmet body 102.

The in-molded energy management liner 200 comprises an inner liner 202and an outer liner 300 (FIGS. 2 and 3). In FIG. 3, the outer liner 300is depicted as transparent to show the structure of the inner liner 202.The inner liner 202 and the outer liner 300 may be formed by molding.The inner liner 202 comprises an inside surface 210, an outside surface212, and sides 214 connecting the inside surface 210 with the outsidesurface 212. The inner liner 202 comprises at least one hole 208 throughthe inner liner 202. The outer liner 300 may be formed around the innerliner 202 such that the outer liner 300 extends through the holes 208and around at least two of the sides 214 of the inner liner 202,covering a majority of the outside surface 212 and at least a portion ofthe inside surface 210. In some embodiments, the outer liner 300 extendsat least partially around all of the sides 214 of the inner liner 202.In some embodiments, both the inner liner 202 and the outer liner 300are exposed on the inside 216 of the in-molded energy management liner200 (FIG. 4). In FIG. 4, the inner liner 202 is depicted in light grayand the outer liner 300 is depicted in dark gray.

The inner liner 202 is made of a first material. The outer liner 300 ismade of a second material. The first material and second materials maybe different. The first and second materials may be of any types ofmaterial used to manage energy impact to the helmet 100. The first andsecond materials may be any types of material that can be expanded and,during the process of molding, formed into bigger objects. Thepre-expanded materials are also called beads. For example, the first orsecond material may be EPS, EPP, EPU, or EPO. In some embodiments, thefirst material is EPP and the second material is EPS.

The inner liner may further comprise one or more standoffs 204. In someembodiments, the standoffs 204 extend outward through the outsidesurface 302 of the outer liner 300. For example, as shown in FIG. 2, thestandoffs 204 can be seen extending outward through the outside surface302 of the outer liner 300. The standoffs may extend from the sides ofthe inner liner through the sides of the outer liner (not shown). Thestandoffs help hold the inner liner in place inside an outer-liner moldwhen the second materials are injected, often at a high speed, into theouter liner mold. The inner liner may be held in place in an outer-linermold through other methods or structures, such as adhesive tapes andhooks-and-loops fasteners.

To assemble a multi-liner helmet, a method 500 may be used (FIG. 5).Method 500 comprises injecting a first material into an inner-liner moldto form an inner liner (502), placing the inner liner in an out-linermold (504), and injecting a second material different from the firstmaterial into the outer-liner mold to form an outer liner around theinner liner (506). The outer liner formed by the method 500 may extendthrough at least one hole in the inner liner and around at least twosides of the inner liner, covering a majority of an outside surface ofthe inner liner, and both the inner liner and the outer liner areexposed on an inside of an in-molded energy management liner comprisingthe inner liner and the outer liner. In some embodiments, the firstmaterial is EPP and the second material is EPS. In some embodiments, theinner-liner comprises one or more standoffs extending outward andinjecting a second material further comprises injecting the secondmaterial such that the standoffs extend outward through an outsidesurface of the outer liner.

When the inner liner and the outer liner are made of differentmaterials, such as having different densities or chemicals, the twomaterials may stay separate and not form a chemical bond under heat andpressure during molding. The holes 208 of the inner liner 202 allow thesecond material for the outer liner to flow through and accumulate onthe inside surface 210 of the inner liner 202 (FIGS. 3 and 4). As aresult, the outer liner 300 is formed around, through, and under theinner liner 202 during the molding, and the two liners 202 and 300 areinterlocked and held together by mechanical forces. No additionalmanufacturing parts or steps are required to hold the liners in theenergy management liner together. Because the liners in the energymanagement liner are co-molded, the multi-liner helmets made in thismanner are also more compact and lighter than those manufactured with aconventional method. Further, the design of the liners, such as thegeometries of the liners, is not constrained by the fastening componentsused to fasten them together and, thus, more design freedom is provided.

This disclosure, its aspects and implementations, are not limited to thespecific components or assembly procedures disclosed herein. Manyadditional components and assembly procedures known in the artconsistent with the intended helmets, co-molded energy managementliners, and methods of assembling a multi-liner helmet will becomeapparent for use with implementations of the apparatus and methods inthis disclosure. In places where the description above refers toparticular implementations of protective helmets, it should be readilyapparent that a number of modifications may be made without departingfrom the spirit thereof and that these implementations may be applied toother protective helmets. The presently disclosed implementations are,therefore, to be considered in all respects as illustrative and notrestrictive, the scope of the disclosure being indicated by the appendedclaims rather than the foregoing description. All changes that comewithin the meaning of and range of equivalency of the description areintended to be embraced therein. Accordingly, for example, althoughparticular helmets, co-molded energy management liners, and methods ofassembling a helmet are disclosed, such apparatus, methods, andimplementing components may comprise any shape, size, style, type,model, version, class, grade, measurement, concentration, material,quantity, the like as is known in the art for such apparatus, methods,and implementing components, and/or the like consistent with theintended operation of the helmet, co-molded energy management liners,and methods of assembling a helmet may be used.

The word “exemplary,” “example,” or various forms thereof are usedherein to mean serving as an example, instance, or illustration. Anyaspect or design described herein as “exemplary” or as an “example” isnot necessarily to be construed as preferred or advantageous over otheraspects or designs. Furthermore, examples are provided solely forpurposes of clarity and understanding and are not meant to limit orrestrict the disclosed subject matter or relevant portions of thisdisclosure in any manner. It is to be appreciated that a myriad ofadditional or alternate examples of varying scope could have beenpresented, but have been omitted for purposes of brevity.

1. A helmet comprising: a helmet body having an outer shell and anin-molded energy management liner inside the outer shell, wherein thein-molded energy management liner includes: an inner liner of expandedpolypropylene (EPP) having at least one hole through the inner liner, aninside surface, an outside surface, and sides connecting the insidesurface with the outside surface; and an outer liner of expandedpolystyrene (EPS) formed around the inner liner such that the outerliner extends through the at least one hole and around at least two ofthe sides of the inner liner, covering a majority of the outside surfaceand at least a portion of the inside surface; and a fit system disposedwithin the in-molded energy management liner and coupled to the helmetbody.
 2. The helmet of claim 1, wherein the inner liner comprises one ormore standoffs extending outward through the outside surface of theouter liner.
 3. The helmet of claim 1, wherein both the inner liner andthe outer liner are exposed on an inside of the in-molded energymanagement liner.
 4. The helmet of claim 1, wherein the outer linerengages the inner liner mechanically and without a chemical bond.
 5. Thehelmet of claim 1, wherein the outer liner extends at least partiallyaround all of the sides of the inner liner.
 6. An in-molded energymanagement liner comprising: an inner liner of expanded polypropylene(EPP) having at least one hole through the inner liner, an insidesurface, an outside surface, and sides connecting the inside surfacewith the outside surface; and an outer liner of expanded polystyrene(EPS) formed around the inner liner such that the outer liner extendsthrough the at least one hole and around at least two of the sides ofthe inner liner, covering a majority of the outside surface and at leasta portion of the inside surface.
 7. The in-molded energy managementliner of claim 6, wherein the inner liner comprises one or morestandoffs extending outward through the outside surface of the outerliner.
 8. The in-molded energy management liner of claim 6, wherein boththe inner liner and the outer liner are exposed on an inside of thein-molded energy management liner.
 9. The in-molded energy managementliner of claim 6, wherein the outer liner engages the inner linermechanically and without a chemical bond.
 10. The in-molded energymanagement liner of claim 6, wherein the outer liner extends at leastpartially around all of the sides of the inner liner.
 11. A method ofassembling a multi-liner helmet, comprising: injecting a first materialinto an inner-liner mold to form an inner liner; placing the inner linerin an outer-liner mold; and injecting a second material different fromthe first material into the outer-liner mold to form an outer lineraround the inner liner; wherein the outer liner extends through at leastone hole in the inner liner and around at least two of sides of theinner liner, covering a majority of an outside surface of the innerliner, and both the outer liner and the inner liner are exposed on aninside of an in-molded energy management liner comprising the innerliner and the outer liner.
 12. The method of claim 11, wherein the firstmaterial is expanded polypropylene (EPP) and the second material isexpanded polystyrene (EPS).
 13. The method of claim 11, wherein theinner liner comprises standoffs extending outward and injecting a secondmaterial comprises injecting the second material such that the standoffsextend outward through an outside surface of the outer liner.
 14. Ahelmet comprising: a helmet body having an outer shell and an in-moldedenergy management liner inside the outer shell, wherein the in-moldedenergy management liner includes: an inner liner of a first materialhaving at least one hole through the inner liner, an inside surface, anoutside surface, and sides connecting the inside surface with theoutside surface, and an outer liner of a second material different fromthe first material formed around the inner liner such that the outerliner extends through the at least one hole and around at least two ofthe sides of the inner liner, covering a majority of the outside surfaceand at least a portion of the inside surface, and both the inner linerand the outer liner are exposed on an inside of the in-molded energymanagement liner.
 15. The helmet of claim 14, further comprising a fitsystem disposed within the in-molded energy management liner and coupledto the helmet body.
 16. The helmet of claim 14, wherein the firstmaterial is EPP and the second material is EPS.
 17. The helmet of claim14, wherein the inner liner comprises one or more standoffs extendingoutward through the outside surface of the outer liner.
 18. The helmetof claim 14, wherein the outer liner engages the inner linermechanically and without a chemical bond.
 19. The helmet of claim 14,wherein the outer liner extends at least partially around all of thesides of the inner liner.